Construction sleeve and method of using the same

ABSTRACT

An apparatus and method for providing a barrier against a material which is setting up, hardening or curing are embodied in a flexible, collapsible, water-resistant sleeve with at least one low-friction surface. In another embodiment, a sleeve material includes a group of such sleeves in a detachably interconnected configuration.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Inventions

[0002] The present inventions relate generally to a sleeve for use inconstruction, more particularly, to a collapsible sleeve including alow-friction surface and a method of using the same.

[0003] 2. Description of the Related Art

[0004] Forms for concrete structures such as building foundations aretypically built with boards or panels. When not suspended, the boards orpanels are held together and in place by wooden or metal stakes that arebetween 1 foot and 4 feet long. The wooden stakes are commonly 1 inch×2inch Douglas Fir, while the metal stakes are commonly ¾ inch diametersteel rods which include holes that allow nails to be driven through therods into the boards or panels. In many instances, the stakes will beembedded in concrete in the region that extends from the ground to thefirst form board after concrete has been poured into the forms. Althoughthe stakes must be removed at some point, stake removal cannot beginuntil the concrete has partially set up. Unfortunately, once theconcrete has partially set up, it sticks to the stakes, which hasheretofore made stake removal a difficult and expensive task. Theremoval of wooden stakes is made even more difficult by the fact thatwooden stakes tend to have a larger surface area than metal stakes, havea rougher surface than metal stakes and, since they are rectangular incross-section, cannot be rotated during removal as can metal stakes thatare circular in cross-section.

[0005] Because of the difficulty associated with removing wooden stakes,especially when the concrete has set more than an optimal amount, thetop portions of the stakes are often broken off at the concrete surface,which leaves the bottom portions of the stakes in the concrete. Leavingthe bottom portions of the wooden stakes in the concrete is problematicfor several reasons. The presence of stakes in the concrete is abuilding code violation and can compromise structural integrity. Thepresence of wooden stakes also provides a “food-filled path” fortermites that allows them to make their way through the concrete into abuilding. As a result, builders are forced to chip the bottom portion ofthe wooden stakes out of the concrete and fill the resulting hole withmortar, which is a costly and time consuming procedure.

[0006] Turning to metal stakes, there are a number of tools that havebeen used to remove metal stakes from concrete. Such tools includeplumbing wrenches, channel lock pliers, hammers, mallets and stakepullers (which are large Class I levers). Unfortunately, the use ofthese tools frequently results in damage to the stakes. Most often, thestakes are bent or their surfaces marred. Damaged metal stakes areproblematic because it is very difficult and, in some instancesimpossible, to extract a damaged stake from concrete. A stuck metalstake must be cut off at the concrete surface (with a saw or torch), orhammered down through the concrete structure into the ground below.

[0007] There is also significant expense associated with the maintenanceof metal stakes. Such maintenance includes the straightening of stakes,keeping the metal surfaces clean and free of cement build-up, andremoving cement from the nail holes. These expenses extend to thosesituations where the metal stakes are rented, as opposed to purchasedoutright. Although stakes can be rented at a relatively low rate, toolrental companies impose significant-penalties when stakes are returnedbent or are not returned at all because they have been cut in half orpounded below the surface of the concrete structure.

[0008] There are also timing issues associated with the use of stakes.Most notably, it is presently necessary to employ a work crew to pourconcrete early in the day and keep the crew on hand while the concretepartially sets up so that, much later in the day, the crew can race toremove the stakes before the concrete fully hardens. As a result, thebuilder is forced to pay a crew to sit around and wait for the concreteto partially set up so that the crew will be there to remove the stakesbefore the concrete hardens.

[0009] All tolled, builders have been heretofore required to spendsignificant amounts of time and money on stake removal and maintenance.These costs, in addition to the costs associated with the injuries thatsometimes occur during stake removal, have resulted in a number ofattempted solutions to the stake removal problem.

[0010] For example, sections of polyvinylchloride (PVC) pipe andplumbing pipe have been used to separate stakes from the surroundingconcrete. The inventor herein has determined that this proposed solutionhas a number of shortcomings. Most notably, the rigid nature of thesepipes requires that they be cut exactly to length because if a pipeextends upwardly beyond the bottom of the first form board, it willdeflect that board, thereby causing disfigurement of the concretestructure. Furthermore, the pipes are expensive, create large voids inthe concrete structure, take up a large amount of storage space, andcannot be used with wooden stakes because a relatively large circularpipe is required to encase a rectangular stake, which results in a largevoid. Also, pipes cannot be removed from the concrete and must be cutoff at the surface of the slab, stem wall or other structure, which istime consuming.

[0011] Another proposed solution is to wrap stakes in filter fabric andthen hold the filter fabric in place with tie wire. The inventor hereinhas determined that this approach is unnecessarily cumbersome,time-consuming and expensive. More over, it does not work well withwooden stakes and it is often virtually impossible to separate thefilter fabric from the concrete.

[0012] Still another proposed solution is to coat the stakes withgrease, diesel fuel, or foam release agents that have been designed tokeep forms (as opposed to stakes) from sticking to concrete. Theinventor herein has determined that these substances are notparticularly effective at preventing stakes from sticking to concreteand, in addition, are labor intensive and messy.

[0013] Another proposed solution is to wrap the stakes in pipeinsulation. The inventor herein has determined that this approach isless than optimal because pipe insulation is bulky, which makes itdifficult to transport and causes it to leave large voids. Pipeinsulation is also expensive

SUMMARY OF THE INVENTIONS

[0014] The inventor herein has determined that a need exists for abetter solution to the aforementioned problems associated with thestakes that are used with forms. More specifically, one object of thepresent invention is to provide an apparatus that will facilitate theremoval of stakes in a manner that is more convenient and cost effectivethan conventional methods.

[0015] In order to accomplish some of these and other objectives, asleeve in accordance with a preferred embodiment of a present inventionincludes flexible, collapsible and water-resistant walls andlow-friction surfaces. The sleeve forms a barrier between a stake orother object and a material, such as concrete, while the material issetting up, hardening or curing. The low-friction inner surface allows astake or other object to be easily removed from the sleeve once theconcrete or other material has set up around the outer surface of thesleeve. The low-friction outer surface allows the sleeve to be easilyremoved from the concrete after the stake has been removed. In analternative embodiment, the outer surface can be formed with a frictionenhancing surface, particularly if it is desirable for the sleeve toremain in the concrete after the concrete has hardened.

[0016] In use, the sleeve may be positioned around a stake or otherobject that will be located within a region into which the concrete orother material will be introduced. Once the concrete has partially setup, the stake or other object can be easily removed because it has notcome into contact with the concrete. Instead, the stake or other objecthas only come into contact with the inner surface of the sleeve, whichis preferably a low friction surface.

[0017] The present sleeve provides a number of other important benefits.For example, the present sleeve is preferably both flexible andcollapsible. These features make the sleeve easier to transport, storeand slip over a stake or other object than pipes and fabric that must beheld in place with tie wire. These features also allow the sheets to bedispensed from a compact holder, roll or the like. The mess andadditional labor associated with the use of grease, diesel fuel, andform release agents are also eliminated. In addition to the low frictioninner surface, the present sleeve is preferably moisture resistant,which prevents the sleeve from soaking up moisture and also allows thesleeve to hold up well in wet conditions associated with the presence ofrain or groundwater.

[0018] The present sleeve is also more cost effective than conventionalstake covering methods. More specifically, the sleeve may be formed froma flat piece of relatively inexpensive sheet material which is foldedlength-wise and glued together to form a sleeve with openings atopposite ends. Suitable sheet material includes the polyboard materialcommonly used in milk cartons. In addition to the savings associatedwith the sleeve itself, the labor costs associated with stake removalwill also be reduced. For example, use of the present invention willeliminate the need for a crew to sit around and wait for the concrete orother material to partially set up so that they can remove the stakesbefore the material fully hardens. This is because the present sleevewill facilitate stake removal even after the material is fully hardened.Thus, a skilled artisan can move from job to job, set up forms and pourconcrete, without the need for separate crews that wait around at eachjob for stake removal. Use of such polyboard material also makes itrelatively easy to cut or tear the sleeves to the appropriate length, ascompared to the pipes used in conventional methods.

[0019] The above described and many other features and attendantadvantages of the present inventions will become apparent as theinventions become better understood by reference to the followingdetailed description when considered in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Detailed description of preferred embodiments of the inventionswill be made with reference to the accompanying drawings.

[0021]FIG. 1A is a front view of an exemplary unassembled sleeve inaccordance with a preferred embodiment of a present invention.

[0022]FIG. 1B is a side view of the unassembled sleeve illustrated inFIG. 1A.

[0023]FIG. 2 is a top view of an exemplary assembled sleeve inaccordance with a preferred embodiment of a present invention in anexpanded position.

[0024]FIGS. 3A, 3B and 3C are front, top and side views, respectively,of the sleeve illustrated in FIG. 2 in a collapsed position.

[0025]FIG. 4 is a perspective view of an exemplary roll of sleevematerial in accordance with a preferred embodiment of a presentinvention.

[0026]FIG. 5A is a perspective view of the sleeve illustrated in FIG. 2with a stake extending therethrough.

[0027]FIG. 5B is a perspective view of the sleeve illustrated in FIG. 2with a tube-shaped member extending therethrough.

[0028]FIG. 6 is a cross-sectional view of a form assembly held togetherwith stakes around which are positioned the sleeve illustrated in FIG.2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] The following is a detailed description of the best presentlyknown mode of carrying out the inventions. This description is not to betaken in a limiting sense, but is made merely for the purpose ofillustrating the general principles of the inventions.

[0030]FIGS. 1A and 1B show an exemplary sleeve 100 according to apresent invention in its unassembled form. The sleeve 100 is preferablya substantially flat sheet of material formed from wood, paper,cardboard, plastic, fiberglass, rubber, metal or natural fibers. In apreferred embodiment, a plurality of substantially parallel, evenlyspaced grooves 102 span along the length of the sleeve 100 and are usedfor folding the sleeve lengthwise during its assembly. The grooves 102are preferably, but not necessarily, rolled onto one side of the sleeve100.

[0031] As discussed in greater detail below with reference to FIGS. 5A,5B and 6, the sleeve 100 can be used to provide a barrier between avariety of different objects, such as form stakes and objects that areused to create a permanent void, and materials which are setting up,hardening or curing. The materials include, but are not limited to,concrete, mortar, plastics, adhesives, plaster, frozen gases or liquids,soil, gravel, glass and metal.

[0032] As illustrated for example in FIG. 2, the sleeve 100 includes aninner surface 104 and an outer surface 106 when in its assembled form.One or both of the surfaces 104 and 106 are preferably a low-friction,reduced friction or slippery surface. The surfaces are also preferablymoisture resistant. In the preferred embodiment, the sleeve 100 isformed from two-sided polyboard material, which is a cardboard andplastic laminate wherein both surfaces of the cardboard are coated witha thermoplastic polymer material that is relatively smooth. Suchpolyboard material, which is commonly used in the production of milkcartons, is known in the paper trade as “S.B.S. with double-sided poly”and “S.B.S. board with poly extruded on both sides.” This material canbe purchased from Fort James Corporation, located in San Ramon, Calif.The preferred thickness of the polyboard material ranges from 14 pointto 20 point (i.e. 0.0014 to 0.0020 meters).

[0033] During assembly, folds are made along the grooves 102 creatingfour side portions (or wall members) and a tab portion 108. An outersurface 110 of the tab portion is then glued to a portion 112 of theinner surface 104 as shown. It should be understood, however, that thesleeve 100 of the present invention is not limited to being four-sided.Rather, a lesser or greater number of grooves can be employed to createsleeves with, for example, two, three, five or six side portions.

[0034] A sleeve 100 with a sufficiently large number of appropriatelyspaced grooves could also be assembled in a variety of different ways.For example, by only folding along certain grooves, the sleeve 100 couldbe assembled such that the ends of the sleeve 100 open to a squareshape. By only folding along different grooves, the sleeve 100 could beassembled as a three-sided sleeve with triangular openings at eitherend. It should also be understood that in order to best fit and servicethe object to be sleeved, a sleeve 100 according to the presentinvention can have other cross-sectional shapes including, but notlimited to, rectangular, oval and circular. In addition, the flexibilityof the sleeve material allows the sleeve 100 to be easily collapsed fortransportation and storage, and expanded for use.

[0035] The sleeve 100 is sized (i.e. length, width and depth selected)and configured (i.e. number of side portions selected) depending uponthe needs of a particular application. For example, the sleeve may besized such that it is slightly larger than a stake or other object withwhich it will be used. This will allow a stake to be moved sideways toloosen its hold in the ground. Turning to conduits, the extra spaceallows for movement should compression or shear motion occur in thesurrounding material. The length of the sleeve may, if desired, beselected to be short enough to handle situations where the depth ofmaterial that is setting up, hardening or curing is relatively low. Anumber of relatively short sleeves can be stacked (or otherwisepositioned) end to end to handle situations involving greater materialdepth.

[0036] The exemplary preferred sleeve 100 shown in FIGS. 3A-3C alsoincludes indicia in the form of hash marks 114 which indicate distancesalong the length of the sleeve 100 such as 0″, 6″, 12″, 18″, etc. Theindicia are useful to a worker who may need to cut the sleeve 100 to alength shorter than its original length. Alternatively, hash marks maybe provided at predetermined intervals without the numeric indicia.

[0037] Another exemplary sleeve, which is generally indicated byreference numeral 200, is illustrated in FIG. 4. The sleeve 200, whichis otherwise identical to the sleeve 100 described above, is relativelylong and includes a plurality of perforations 202. The perforations 202separate the sleeve 200 into a plurality of readily detachableindividual sleeves 204. In the illustrated embodiment, the sleeves 204are attached end-to-end by the perforations 202 and may be separatedfrom each other as desired by tearing across the sleeve material at theperforations 202.

[0038] As illustrated for example in FIG. 4, the flexibility of thesleeve material allows the sleeves 204, while collapsed, to be storedand/or dispensed in a compact fashion by coiling them around a roll 206.Other storage and dispenser mechanisms, such a box or container whichwould not require the sleeves 204 to be coiled or bent, are alsosuitable. Here, the sleeves 200 could be folded at each line ofperforations 202 (or every other line of perforations) in zig-zagfashion. It should also be understood that the sleeves 100 and 204 canbe detachably interconnected in other manners such as, for example, byattaching them to one another other side-to-side with tape or anothereasily removable fastening device.

[0039] Turning to FIG. 5A, a stake 300 is shown after having beeninserted into a sleeve 100. The exemplary flexible, collapsible,water-resistant sleeve 100 (or 204), with its low-friction innersurface, may be used with both wood and metal stakes 300. The exemplarysleeve 100 (or 204) may also be used in conjunction with a void formingmember 302 that is used to form a void in the material which is settingup, hardening or curing. Such voids may be ultimately used for drains,or for passageways in the structure being built. Also, although both thestake 300 and the void forming member 302 are shown as being tube-shapedor cylindrical, it should be understood that the sleeve 100 (or 204) canaccommodate objects that are shaped otherwise.

[0040] The sleeve 100 is also useful for other structural, architecturaland artistic purposes. For example, it can also be used to surroundtension cables, gas and liquid plumbing pipes, electrical wires andconduits, dowels, air passage ways, Lucite™ tubing and pressurizedhoses, pipes or conduits.

[0041] In accordance with an invention herein, a method of providing abarrier between a material which is setting up, hardening or curing anda stake or other object may be practiced with the sleeves describedabove. Generally, the object to be separated from the material is firstslid into a sleeve, or the sleeve onto the object. Then the object isdriven into the ground, soil or other foundational material such thatthe sleeve remains exposed and is positioned within the volumetric areainto which a material such as concrete will be introduced.

[0042] Turning to FIG. 6, a form assembly 600 is shown held togetherwith stakes 300 around which are positioned sleeves 100. The formassembly 600 includes a plurality of boards 602 which are attached tothe stakes 300 with nails 604 or the like after the stakes 300 aredriven into the soil 606. Next, a material such as concrete 608 isintroduced as shown. This may, or may not, change the shape of thesleeves 100. When the surrounding material has reached its desired stateof hardness, or elasticity, the encased objects (here, the stakes 300)can be left in place or extracted from the sleeves 100 at any time, evenafter the surrounding material has fully hardened or cured. Thisextraction is readily accomplished because the sleeves 100 reducefriction and suction. If desired, once the stakes 300 are removed, thesleeves 100 can be extracted from the concrete 608. The resulting voidcan be used for reinserting the original sleeved object, a cane-boltmechanism or another substance (such as something harder, or of adifferent color, than the surrounding material.)

[0043] Although the present invention has been described in terms of thepreferred embodiment above, numerous modifications and/or additions tothe above described preferred embodiments would be readily apparent toone skilled in the art. By way of example, but not limitation, thesleeve can be made without the grooves. It is intended that the scope ofthe present invention extends to all such modifications and/oradditions.

I claim:
 1. An apparatus for use as a barrier between a material whichis setting up, hardening or curing and an object, the apparatuscomprising: at least two wall members defining respective longitudinalends and inner surfaces connected to one another such that the innersurfaces define a region therebetween having at least one openlongitudinal end and of sufficient size to receive the object therein;and at least one of the inner surfaces being a relatively low frictionsurface which the object tends to slip over rather than adhere to.
 2. Anapparatus as claimed in claim 1 , wherein the at least two wall membersare connected to one another such that the apparatus can be expanded andcollapsed.
 3. An apparatus as claimed in claim 1 , wherein the at leasttwo wall members comprise at least four members.
 4. An apparatus asclaimed in claim 1 , wherein the at least two wall members are separatedby a fold line.
 5. An apparatus as claimed in claim 1 , wherein the atleast two wall members include a water-resistant surface.
 6. Anapparatus as claimed in claim 1 , wherein at least one of the wallmembers includes visible indicia indicating distances along a length ofthe sleeve.
 7. An apparatus as claimed in claim 6 , wherein the indiciacomprises hash marks.
 8. An apparatus as claimed in claim 1 , whereinthe wall members are formed at least in part with paper.
 9. An apparatusas claimed in claim 1 , wherein the wall members are formed at least inpart with cardboard.
 10. An apparatus as claimed in claim 1 , whereinthe wall members are formed at least in part with plastic.
 11. Anapparatus for use as a barrier between a material which is setting up,hardening or curing and an object, the apparatus comprising: at leasttwo sleeves, each sleeve defining a region having at least one openlongitudinal end and of sufficient size to receive the object therein;and an apparatus releasably connecting the at least two sleeves to oneanother.
 12. An apparatus as claimed in claim 11 , wherein the sleevesdefine longitudinal ends and are connected end-to-end.
 13. An apparatusas claimed in claim 11 , wherein the sleeves are formed from a sleevematerial and the apparatus comprises small portions of sleeve materialseparated by perforations.
 14. A method of providing a barrier between amaterial which is setting up, hardening or curing and an object, themethod comprising the steps of: providing a sleeve defining a regionhaving at least one open longitudinal end and of sufficient size toreceive the object therein; positioning the sleeve and the object withinan area into which the material will be introduced, with the objectbeing at least partially fitted inside the sleeve; introducing thematerial into the area; and removing the object from the sleeve.
 15. Amethod as claimed in claim 14 , further comprising the step of: removingthe sleeve from the material.
 16. A method as claimed in claim 14 ,wherein the object comprises a stake.
 17. A method as claimed in claim16 , wherein the stake comprises a wooden stake.
 18. A method as claimedin claim 16 , wherein the stake comprises a metal stake.
 19. A method asclaimed in claim 19 , wherein the object is a void forming member. 20.An apparatus for use as a barrier between a material which is settingup, hardening or curing and an object, the apparatus comprising: atubular member defining open longitudinal ends and an inner surfaceenclosing a region of sufficient size to receive the object therein; andthe inner surface being a relatively low friction surface which theobject tends to slip over rather than adhere to.
 21. An apparatus asclaimed in claim 20 , wherein the tubular member comprises polyboardmaterial.
 22. An apparatus as claimed in claim 20 , wherein the tubularmember has a circular cross-section.
 23. An apparatus as claimed inclaim 20 , wherein the tubular member has a non-circular cross-section.24. An apparatus as claimed in claim 20 , wherein the tubular memberincludes at least one fold line.